Vehicle hvac unit having integrated retaining system

ABSTRACT

A heating, ventilation, and air condition (HVAC) unit includes a casing, a mount, and one or more flexible fingers. The casing is configured to condition air and direct the conditioned air to a vehicle occupant cabin. The mount extends from the casing and is configured to be mounted to an attachment surface. The mount includes an opening that has an inner surface. The flexible fingers each have a proximal end that extends from the inner surface and a distal end. One or more of the distal ends of the flexible fingers are configured to engage an attachment feature extending from the attachment surface and through the opening in the mount to secure the mount to the attachment feature.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a U.S. patent application, which claims priority toand the benefit of U.S. Provisional Patent Application No. 63/122,511filed Dec. 8, 2020. The disclosures of the above applications areincorporated herein by reference.

FIELD

The present disclosure relates to a vehicle HVAC unit having anintegrated retaining system.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

A typical vehicle includes a heating, ventilation, and air conditioning(HVAC) unit that may be coupled to a vehicle dashboard and that providesconditioned air (e.g., heated and/or cooled and/or dehumidified orhumidified and/or filtered) to a vehicle occupant cabin via one or moreduct lines. During assembly of the HVAC unit to the vehicle dashboard,an operator typically positions the HVAC unit onto studs extending fromthe vehicle dashboard and then grabs a tool to torque fastening nutsonto the studs, thereby securing the HVAC unit to the vehicle dashboard.The HVAC unit may become disengaged from the studs once the operatortakes his or her hands off the HVAC unit to grab a tool, for example.The present disclosure provides an HVAC unit that solves this and otherissues associated with typical HVAC units.

SUMMARY

This section provides a general summary of the disclosure and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present disclosure discloses a heating, ventilation,and air condition (HVAC) unit including a casing, a first mount, and oneor more first flexible fingers. The casing is configured to directconditioned air to a vehicle occupant cabin. The first mount extendsfrom the casing and is configured to be mounted to an attachmentsurface. The first mount includes a first opening having a first innersurface. The first flexible fingers each has a proximal end extendingfrom the first inner surface and a distal end. One or more of the distalends of the first flexible fingers are configured to be engaged with afirst attachment feature extending from the attachment surface andthrough the first opening in the first mount to secure the first mountto the first attachment feature.

In some configurations, each first finger is tapered from the proximalend towards the distal end.

In some configurations, the distal ends of the first flexible fingerscooperate to form a circular-shaped opening. The circular-shaped openingis configured to receive the first attachment feature of the attachmentsurface.

In some configurations, the first inner surface is acircumferentially-shaped inner surface. The first flexible fingers arecircumferentially spaced around the circumferentially-shaped innersurface.

In some configurations, the first inner surface is acircumferentially-shaped inner surface. The first flexible fingersextend radially inwardly from the circumferentially-shaped innersurface.

In some configurations, the first flexible fingers have a firstthickness and the first mount has a second thickness. The secondthickness is equal to or greater than the first thickness.

In some configurations, the HVAC unit further includes a second mountand one or more second flexible fingers. The second mount extends fromthe casing and is configured to be mounted to the attachment surface.The second mount includes a second opening having a second innersurface. The second flexible fingers each having a proximal endextending from the second inner surface and a distal end. One or more ofthe distal ends of the second flexible fingers are configured to engagea second attachment feature extending from the attachment surface andthrough the second opening in the second mount to secure the secondmount to the second attachment feature.

In another form, the present disclosure discloses a heating,ventilation, and air condition (HVAC) unit including a casing, a mountand a retaining washer. The casing is configured to direct conditionedair to a vehicle occupant cabin. The mount extends from the casing andis configured to be mounted to an attachment surface. The mount includesa slot and an opening. The retaining washer is moveably disposed withinthe slot and includes one or more flexible retaining features eachhaving a proximal end and a distal end. One or more of the distal endsof the flexible retaining features are configured to be engaged with anattachment feature extending from the attachment surface and through theopening in the mount to secure the mount to the attachment feature.

In some configurations, the opening includes a first innercircumferential surface having a first diameter and the slot includes asecond inner circumferential surface having a second diameter. Thesecond diameter is greater than the first diameter.

In some configurations, the mount includes a first axial end surface anda second axial end surface. The slot is formed in the mount between thefirst axial end surface and the second axial end surface.

In some configurations, the mount includes a first member and a secondmember removably coupled to the first member. The first and secondmembers cooperate to form the opening having a circular shape.

In some configurations, the retaining washer includes a body portionhaving an aperture formed therein. The flexible retaining featuresextend radially inwardly from an inner circumferential surface of theaperture.

In some configurations, each retaining feature is tapered from theproximal end towards the distal end.

In some configurations, the distal ends of the flexible retainingfeatures cooperate to form a circular-shaped opening. Thecircular-shaped opening is configured to receive the attachment featureof the attachment surface.

In some configurations, the circular-shaped opening is within theopening in the mount.

In yet another form, the present disclosure discloses a method forcoupling a heating, ventilation, and air condition (HVAC) unit to anattachment surface. The method includes providing the attachment surfacehaving at least one attachment feature extending therefrom, aligning anopening formed in a mount of the HVAC unit with the at least oneattachment feature of the attachment surface, and inserting the at leastone attachment feature through the opening such that one or moreflexible fingers associated with the mount engage the at least oneattachment feature to secure the mount to the at least one attachmentfeature.

In some configurations, each flexible finger includes a proximal end anda distal end. Each flexible finger is tapered from the proximal endtowards the distal end.

In some configurations, distal ends of the flexible fingers cooperate toform a circular-shaped opening. The circular-shaped opening is withinthe opening in the mount.

In some configurations, inserting the at least one attachment featurethrough the opening in the mount includes inserting the at least oneattachment feature through the circular-shaped opening formed by thedistal ends of the flexible fingers.

In some configurations, the flexible fingers extend from an innercircumferential surface of the opening formed in the mount.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which:

FIG. 1 is a schematic view of a representative vehicle including aheating, ventilation, and air conditioning (HVAC) unit in accordancewith the present teachings;

FIG. 2 is a perspective view of the HVAC unit exploded from a vehicledashboard;

FIG. 3 is a close-up perspective view of the area indicated as area 3 ofFIG. 2;

FIG. 4 is a perspective view of the HVAC unit of FIG. 2 assembled to thevehicle dashboard;

FIG. 5 is a close-up perspective view of the area indicated as area 5 ofFIG. 4;

FIG. 6 is a close-up perspective view similar to FIG. 5, illustrating amount of the HVAC unit positioned onto a stud of the vehicle dashboardwith a nut threadably engaged to the stud;

FIG. 7 is a perspective view of a portion of an alternate HVAC unit inaccordance with the teachings of the present disclosure;

FIG. 8 is a close-up perspective view of the area indicated as area 8 ofFIG. 7;

FIG. 9 is a close-up perspective view of a mount of the HVAC unit ofFIG. 7 with a first member of the mount and a second member of the mountexploded from each other; and

FIG. 10 is a cross-sectional view taken along line 10-10 of FIG. 8.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses. Itshould be understood that throughout the drawings, correspondingreference numerals indicate like or corresponding parts and features.

As shown in FIG. 1, a vehicle 10 having a heating, venting, and aircooling (HVAC) unit 12 is provided. The HVAC unit 12 is disposed in afront portion 14 of the vehicle 10. The HVAC unit 12 may provide airflow(e.g., heated and/or cooled) to a front region 16 of a vehicle cabin 18via a front set of duct lines (not shown) and/or a rear region 20 of thevehicle cabin 18 via a rear set of duct lines (not shown). Withreference to FIGS. 2-6, the HVAC unit 12 is coupled to a vehicledashboard 21 and includes a casing 22 (FIGS. 2 and 4) and a plurality ofmounts 24.

The casing 22 may be formed of one or more shells and may include afirst inlet opening 26, a second inlet opening (not shown), and one ormore outlet opening (not shown). Air conditioning components such as anevaporator (not shown) and a heater core (not shown) may be disposedwithin the casing 22 to heat and/or cool air flowing therethrough. Forexample, ambient air may be drawn in through the first inlet opening 26where it is conditioned (e.g., heated and/or cooled) prior to exitingthe outlets into the vehicle cabin 18 via the front set of duct linesand/or the rear set of duct lines. In another example, cabin air may bedrawn in through the second inlet opening where it is conditioned priorto exiting the outlets into the vehicle cabin 18 via the front set ofduct lines and/or the rear set of duct lines.

As shown in FIGS. 2-6, each mount 24 extends from the casing 22 and isconfigured to be coupled to the vehicle dashboard 21. Each mount 24 hasa generally circular shape and includes an outer circumferential surface27 and a circular-shaped opening 28 having an inner circumferentialsurface 29 (FIGS. 3 and 5). In some configurations, the opening 28 maybe triangular, rectangular, or any other suitable shape.

A plurality of flexible fingers or retaining features 30 arecircumferentially spaced apart around the inner circumferential surface29 of a respective mount 24 and extend radially inwardly from the innercircumferential surface 29 of the respective mount 24 (the flexiblefingers 30 are cantilevered to the mount 24). The flexible fingers 30are also positioned between first and second end surfaces 31 a, 31 b ofthe mount 24. The flexible fingers 30 may be made of a polymericmaterial, for example, or any other suitable material that is allowed tobend or flex. The mount 24 has a thickness (i.e., the distance betweenthe first and second end surfaces 31 a, 31 b) that is equal to orgreater than a thickness of the flexible fingers 30. The flexiblefingers 30 and the mount 24 are manufactured as a single piece(manufactured from a single molded part).

As shown best in FIGS. 3 and 5, each flexible finger 30 has a proximalend 32 (i.e., proximal to the inner circumferential surface 29) and adistal end 34 (i.e., distal to the inner circumferential surface 20).Each flexible finger 30 is tapered from the proximal end 32 towards thedistal end 34. In this way, a width of the proximal end 32 is greaterthan a width of the distal end 34. The distal ends 34 of the flexiblefingers 30 may cooperate to form a generally circular-shaped opening 36(FIG. 3) having a diameter that is less than a diameter of thecircular-shaped opening 28. The opening 36 is positioned within theopening 28 of the mount 24 and is configured to receive a respectivethreaded attachment feature or stud 38 extending from an attachmentsurface 39 of the vehicle dashboard 21. It is understood that the lengthof some of the flexible fingers 30 shown may be longer than otherflexible fingers 30. However, in some configurations (not shown), theycan all be the same length or have different configurations of lengthsthan shown.

With continued reference to FIGS. 1-6, assembly (i.e., a method ofassembling) of the HVAC unit 12 to the vehicle dashboard 21 will now bedescribed in detail. First, the vehicle dashboard 21 is provided. Thethreaded studs 38 extend from the attachment surface 39 of the vehicledashboard 21.

Next, as shown in FIG. 2, an operator (not shown) aligns the opening 28of each mount 24 of the HVAC unit 12 with a respective stud 38 of thevehicle dashboard 21. Next, as shown in FIGS. 4 and 5, the operator (notshown) positions each mount 24 onto the respective stud 38 (the stud 38extends through the opening 36 formed by the flexible fingers 30) suchthat one or more flexible fingers 30 extending from the innercircumferential surface 29 of the mount 24 engage the respective stud 38to inhibit the mount 24 from disengaging from the respective stud 38(secure the mount 24 onto the respective stud 38). Stated differently,the distal end 34 of one or more flexible fingers 30 engages threads ofthe stud 38, thereby inhibiting the mount 24 from disengaging from thestud 38 once the operator (not shown) takes his or her hands off of theHVAC unit 12 to grab a tool (not shown), for example. It should beunderstood that one or more of the flexible fingers 30 are allowed tobend or flex to accommodate tolerances between the stud 38 and theopening 36 while also engaging the stud 38 to inhibit the mount 24 fromdisengaging from the stud 38.

Finally, as shown in FIG. 6, the operator (not shown) torques a nut 40onto each stud 38 using the tool, thereby applying clamping force to thefirst end surface 31 a, further securing the HVAC unit 12 to the vehicledashboard 21. In the example provided, an optional washer 42 can bedisposed between the nut 40 and the first end surface 31 a.

The flexible fingers 30 of the present disclosure provide the benefit ofsecuring the mounts 24 to the studs 38 when the operator takes his orher hands off of the HVAC unit 12 after the mounts 24 are initiallypositioned onto the studs 38 and before the operator torques the nut 40onto each stud 38.

With reference to FIGS. 7-10, another HVAC unit 112 is provided. TheHVAC unit 112 may be incorporated into the vehicle 10 described aboveinstead of HVAC unit 12. The structure and function of the HVAC unit 112may be similar or identical to that of HVAC unit 12 described above,apart from any exceptions noted below.

The HVAC unit 112 may be coupled to the vehicle dashboard 21 andincludes a casing 121 (FIG. 7) and a plurality of mounts 124 (only oneshown in the figures). The structure and function of casing 121 may besimilar or identical to casing 22 described above, and therefore, willnot be described again in detail.

Each mount 124 is coupled to the vehicle dashboard 21 (FIG. 2). As shownin FIGS. 7-10, each mount 124 includes a first connecting member 102 anda second connecting member 103. The first connecting member 102 extendsfrom the casing 121 and includes a body portion 104 and a pair of flangeportions 106 a, 106 b. The body portion 104 has a semi-circular shapeand includes a semi-circular opening 115 and a semi-circular slot 117(FIGS. 9 and 10). The opening 115 is formed along an edge 107 of thebody portion 104 at a center thereof. The slot 117 is formed in the bodyportion 104 between a first end surface 108 and a second end surface 110of the body portion 104 (FIG. 9). Each flange portion 106 a, 106 bextends radially outwardly from a periphery of the body portion 104.

With reference to FIG. 7-10, the second connecting member 103 isremovably coupled to the first connecting member 102 and includes a bodyportion 114 and a pair of flange portions 116 a, 116 b. The body portion114 has a semi-circular shape and includes a semi-circular opening 113and a semi-circular slot 118 (FIGS. 9 and 10). The opening 113 is formedalong a flat edge 120 of the body portion 114 at a center thereof. Theslot 118 is formed in the body portion 114 between a first end surface122 and a second end surface (not shown) of the body portion 114. Eachflange portion 116 a, 116 b extends radially outwardly from a peripheryof the body portion 114 and includes an opening 128 that is aligned witha respective opening 130 of the flange portions 106 a, 106 b.

A first fastener (not shown, e.g., a screw or bolt) may extend throughthe opening 128 of the flange portion 116 a and the opening 130 of theflange portion 106 a and a second fastener (not shown, e.g., a screw orbolt) may extend through the opening 128 of the flange portion 116 b andthe opening 130 of the flange portion 106 b. In this way, the first andsecond connecting members 102, 103 are connected to each other. When thefirst and second connecting members 102, 103 are connected to eachother, the opening 115 of the first connecting member 102 and theopening 113 of the second connecting member 103 cooperate to form acircular-shaped opening 132 (FIG. 8), and the slot 117 of the firstconnecting member 102 and the slot 118 of the second connecting member103 cooperate to form a circular-shaped slot 134 (FIG. 10). A diameterof the circular-shaped slot 134 is greater than a diameter of thecircular-shaped opening 132.

A separate retaining washer 136 is movably disposed within the slot 134formed by the first and second connecting members 102, 103 (FIG. 10).That is, while the second connecting member 103 is decoupled from thefirst connecting member 102, the retaining washer 136 is disposed in oneof the slots 117, 118 of the first and second connecting members 102,103 prior to coupling the second connecting member 103 to the firstconnecting member 102.

As shown best in FIGS. 8-10, the retaining washer 136 includes a bodyportion 138 and a plurality of flexible fingers or retaining features140. The body portion 138 is circular-shaped and can include acircular-shaped aperture 142 formed therein. The body portion 138 alsohas an outer circumferential surface 143 that may optionally engage aportion of an inner circumferential surface 144 (FIG. 10) of the slot134. In the example provided, diameter of the inner circumferentialsurface 144 is greater than a diameter of the outer circumferentialsurface 143 such that the retaining washer 136 may move within the slot134, though other configurations can be used such as having similardiameters. In some configurations, not specifically shown, the outercircumferential surface 143 may be hexagonal, octagonal or any othersuitable shape instead of circumferential. In some configurations, notspecifically shown, the slot 134 may be hexagonal, octagonal, or anyother suitable shape instead of circular.

The flexible fingers 140 are circumferentially spaced apart around aninner circumferential surface 146 of the aperture 142 and extendradially inwardly from the inner circumferential surface 146 of theaperture 142 (the flexible fingers 140 are cantilevered to the bodyportion 138 of the retaining washer 136). The flexible fingers 140 maybe made of a polymeric material, for example, or any other suitablematerial that is allowed to bend or flex. The mount 124 has a thicknessthat is equal to or greater than a thickness of the flexible fingers140.

Each flexible finger 140 has a proximal end 148 (i.e., proximal theinner circumferential surface 146) and a distal end 150 (i.e., distal tothe inner circumferential surface 146). Each flexible finger 140 istapered from the proximal end 148 towards the distal end 150. In thisway, a width of the proximal end 148 is greater than a width of thedistal end 150. The distal ends 150 of the flexible fingers 140 maycooperate to form a generally circular-shaped opening 154 having adiameter that is less than a diameter of the circular-shaped opening 132formed by the first and second connecting members 102, 103. The opening154 is positioned within the opening 132 and is configured to receive arespective threaded stud 38 extending from the vehicle dashboard 21.Stated differently, the opening 154 formed by the flexible fingers 140is always accessible from the opening 132 regardless of the movement ofthe retaining washer 136 within the slot 134 formed by the first andsecond connecting members 102, 103 (the retaining washer 136 is allowedto move within the slot 134 to accommodate tolerances between the stud38 and the opening 154). It should be understood that one or more of theflexible fingers 140 are allowed to bend or flex to accommodatetolerances between the stud 38 and the opening 154 while also engagingthe stud 38 to secure the mount 124 to the stud 38. In the exampleprovided, the length of each flexible finger 140 shown in the figuresare equal to each other. However, in some configurations, the lengths ofthe flexible fingers 140 may be different and may be similarly arrangedas the flexible fingers 30 (FIG. 3).

Unless otherwise expressly indicated herein, all numerical valuesindicating mechanical/thermal properties, compositional percentages,dimensions and/or tolerances, or other characteristics are to beunderstood as modified by the word “about” or “approximately” indescribing the scope of the present disclosure. This modification isdesired for various reasons including industrial practice, material,manufacturing, and assembly tolerances, and testing capability.

As used herein, the phrase at least one of A, B, and C should beconstrued to mean a logical (A OR B OR C), using a non-exclusive logicalOR, and should not be construed to mean “at least one of A, at least oneof B, and at least one of C.”

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the substance of the disclosureare intended to be within the scope of the disclosure. Such variationsare not to be regarded as a departure from the spirit and scope of thedisclosure.

What is claimed is:
 1. A heating, ventilation, and air condition (HVAC)unit comprising: a casing configured to direct conditioned air to avehicle occupant cabin; a first mount extending from the casing andconfigured to be mounted to an attachment surface, the first mountincluding a first opening having a first inner surface; and one or morefirst flexible fingers each having a proximal end and a distal end, theproximal end extending from the first inner surface, wherein one or moreof the distal ends of the one or more first flexible fingers areconfigured to be engaged with a first attachment feature extending fromthe attachment surface and through the first opening in the first mountto secure the first mount to the first attachment feature.
 2. The HVACunit according to claim 1, wherein each first finger is tapered from theproximal end towards the distal end.
 3. The HVAC unit according to claim1, wherein the distal ends of the one or more first flexible fingerscooperate to form a circular-shaped opening, and wherein thecircular-shaped opening is configured to receive the first attachmentfeature of the attachment surface.
 4. The HVAC unit according to claim1, wherein the first inner surface is a circumferentially-shaped innersurface, and wherein the one or more first flexible fingers arecircumferentially spaced around the circumferentially-shaped innersurface.
 5. The HVAC unit according to claim 1, wherein the first innersurface is a circumferentially-shaped inner surface, and wherein the oneor more first flexible fingers extend radially inwardly from thecircumferentially-shaped inner surface.
 6. The HVAC unit according toclaim 1, wherein the one or more first flexible fingers have a firstthickness and the first mount has a second thickness, and wherein thesecond thickness is equal to or greater than the first thickness.
 7. TheHVAC unit according to claim 1, further comprising: a second mountextending from the casing and configured to be mounted to the attachmentsurface, the second mount including a second opening having a secondinner surface; and one or more second flexible fingers each having aproximal end extending from the second inner surface and a distal end,wherein one or more of the distal ends of the one or more secondflexible fingers are configured to engage a second attachment featureextending from the attachment surface and through the second opening inthe second mount to secure the second mount to the second attachmentfeature.
 8. A heating, ventilation, and air condition (HVAC) unitcomprising: a casing configured to direct conditioned air to a vehicleoccupant cabin; a mount extending from the casing and configured to bemounted to an attachment surface, the mount including a slot and anopening; and a retaining washer moveably disposed within the slot andincluding one or more flexible retaining features each having a proximalend and a distal end, wherein one or more of the distal ends of the oneor more flexible retaining features are configured to be engaged with anattachment feature extending from the attachment surface and through theopening in the mount to secure the mount to the attachment feature. 9.The HVAC unit according to claim 8, wherein the opening includes a firstinner circumferential surface having a first diameter and the slotincludes a second inner circumferential surface having a seconddiameter, and wherein the second diameter is greater than the firstdiameter.
 10. The HVAC unit according to claim 8, wherein the mountincludes a first axial end surface and a second axial end surface, andwherein the slot is formed in the mount between the first axial endsurface and the second axial end surface.
 11. The HVAC unit according toclaim 8, wherein the mount includes a first member and a second memberremovably coupled to the first member, and wherein the first and secondmembers cooperate to form the opening having a circular shape.
 12. TheHVAC unit according to claim 8, wherein the retaining washer includes abody portion having an aperture formed therein, and wherein the one ormore flexible retaining features extend radially inwardly from an innercircumferential surface of the aperture.
 13. The HVAC unit according toclaim 8, wherein each retaining feature is tapered from the proximal endtowards the distal end.
 14. The HVAC unit according to claim 8, whereinthe distal ends of the one or more flexible retaining features cooperateto form a circular-shaped opening, and wherein the circular-shapedopening is configured to receive the attachment feature of theattachment surface.
 15. The HVAC unit according to claim 14, wherein thecircular-shaped opening is within the opening in the mount.
 16. A methodfor coupling a heating, ventilation, and air condition (HVAC) unit to anattachment surface, the method comprising: providing the attachmentsurface, the attachment surface having at least one attachment featureextending therefrom; aligning an opening formed in a mount of the HVACunit with the at least one attachment feature of the attachment surface;and inserting the at least one attachment feature through the openingsuch that one or more flexible fingers associated with the mount engagethe at least one attachment feature to secure the mount to the at leastone attachment feature.
 17. The method according to claim 16, whereineach flexible finger includes a proximal end and a distal end, andwherein each flexible finger is tapered from the proximal end towardsthe distal end.
 18. The method according to claim 16, wherein distalends of the one or more flexible fingers cooperate to form acircular-shaped opening, and wherein the circular-shaped opening iswithin the opening in the mount.
 19. The method according to claim 18,wherein inserting the at least one attachment feature through theopening in the mount includes inserting the at least one attachmentfeature through the circular-shaped opening formed by the distal ends ofthe flexible fingers.
 20. The method according to claim 16, wherein theone or more flexible fingers extend from an inner circumferentialsurface of the opening formed in the mount.